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Integrity management and inspection

Integrity management and inspection

TÜV Rheinland helps process industry companies improve the integrity of their operations and assets. TÜV Rheinland's risk-based approach reduces safety and business risks cost effectively.

Regulation, aging assets, poor reliability and skills shortages drive many manufacturing companies to reassess their focus on all components of integrity management including the assets, systems and people. TÜV Rheinland brings a well-respected and independent approach to any stage of the improvement process.

TÜV Rheinland´s pRIME (process Reliability and Integrity Management Excellence) program combines leading methodologies and tools with expert technical judgement to initially identify and then deliver integrity improvements. We prioritize the key areas to address, rather than unnecessarily assessing areas with no scope for beneficial improvement.

Our offerings

Safe and reliable assets, effective systems and competent people.


The start point for improving integrity is to understand the current situation.

Asset health checks

pRIME signpost rapidly assesses manufacturing operations across the key areas of integrity and identifies any gaps versus best practice. The output is a prioritised list of improvements.

  • Tailored studies - Focus only on the areas of concern and match resources to the size of the assets
  • Efficient methods - Minimise the time and cost of the study and reduce the requirements placed on your operating teams.

As with all of TÜV Rheinland's integrity offering a risk based approach focuses on the vulnerable areas across production assets, systems and people, using experienced consultants and bespoke software tools.

The first step towards improved integrity.


TÜV Rheinland's asset life assessment identifies the investments (money and resources) required in an asset to achieve their desired performance throughout a defined lifetime, typically 10-20 years.

Asset life studies

The study provides the following topics:

  • An overview of deterioration modes and equipment status
  • Detailed life assessments and required action plans for key equipment
  • Overall asset investment profile over the study period
  • Improvement plans for the asset supporting processes

As with all of TÜV Rheinland's integrity offering a risk based approach focuses on the vulnerable areas across production assets, systems and people, using experienced consultants and bespoke software tools.

Understanding the investment needed to sustain assets.


pRIME signpost* is used to assess the condition of manufacturing facilities and the supporting systems, prior to a potential acquisition.

Technical Due-Diligence (TDD)

  • The study identifies any issues with legislative compliance
  • The study identifies any imminent safety or reliability issues
  • The study assesses the condition of the assets, system and maintenance organisation
  • The study allows required investments to be planned

Understand before buying.


Understanding what is required to improve integrity is a key first step, but often companies fail to deliver desired improvements.

Integrity improvement projects

Possible reasons include a lack of resource, a lack of technical competence and experience, a lack of change / project management resource or competing priorities.

TÜV Rheinland helps to deliver sustainable integrity improvements whether it is involved in identifying the opportunities or not. TÜV Rheinland's support can come in many forms including:

  • Technical training
  • System and procedure development
  • Engineering consultancy or design
  • Programme management
  • Running business improvement and change teams


Leading provider of 3rd party pressure systems inspections in the UK and the North Sea.

Pressure systems and tank inspection

Accredited by the United Kingdom Accreditation Service (UKAS), TÜV Rheinland supplies a full inspection service - inspection scheduling and planning, inspection and reporting, reviewing and updating schemes of examination.

The TÜV Rheinland approach is to develop risk based schemes of examination that focus the inspection effort into the areas of highest risk. The approach leads to more effective and cost efficient inspections and optimises the amount of NDT work required.

TÜV Rheinland's inspection team works closely with its design team and through specialist design services advises on / rectifies defects found during inspection.

Our inspection services are applied to pressure systems covered by the Pressure Systems Safety Regulations (PSSR) and to other equipment, such as pipework and tanks.

Management of plant integrity.


Risk Based Inspection (RBI)

TÜV Rheinland provides a range of Risk Based Inspection (RBI) services:

  • RBI studies - using our proprietary methodology and tools
  • Focussed schemes of examination service - updating inspection schemes to reflect the outcomes for RBI studies
  • Screening studies - a rapid assessment of equipment to prioritise items for full RBI studies

Our approach to RBI uses qualitative and semi-quantitative methods utilising real operating experience to optimise inspection schemes and intervals. RBI can be carried out on a variety of types of equipment (e.g. pressure systems, rotating equipment, structures, etc.)

RBI can be carried out on a variety of types of equipment (e.g. pressure systems, rotating equipment, structures, etc.) Our RBI follows TÜV Rheinland’s RBI+© methodology and uses the RBI+© pRIME tool. To see how RBI+© pRIME software can benefit your business try our free demo at:


NII is a approach commonly used in process industries where it has provided significant financial benefits without compromising safety.

Non-Intrusive Inspection (NII)

NII allows pressure vessels to be inspected with the equipment online and avoids entry into confined spaces to perform the investigation.

NII helps shorten turnarounds (TARs) by reducing the amount of intrusive work during the event allowing it, where possible, to be completed at other times when the asset is online.

Minimising plant downtime is a business imperative in the process industries. The inspection of equipment, to maintain safe operation and fulfil statutory requirements, is a major driver of the frequency and duration of planned outages. Reducing plant downtime has a significant benefit to the bottom line.

Our reference cases

pdf MOL Group chooses TÜV Rheinland and Metegrity 1 MB Download

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